Packaging, particularly a palletizable packaging, a pallet carrying it and their methods of manufacture

ABSTRACT

The packaging ( 100 ) contains pouches ( 2   a   , 2   b   , 2   c   , 2   d ) which are placed head-to-tail in it and the packaging is of the flexible type with four welded sides ( 101   a   , 101   b   , 101   c   , 101   d ). The pouches can be of the doypack type or of a flat uniform or pillow pouch type in which case they are placed so as to be staggered. A plurality of such packagings can advantageously be put on a pallet with the pouches arranged flat in relation to the pallet.

The invention relates to a novel box, in particular a palletizablepackaging, to the pallet comprising this packaging, and to their methodsof manufacture.

Various types of packaging are known such as primary packages containedin other packages called secondary packages. It is known, for example,to pack a cardboard box (secondary package) with units (primary package)such as pouches, in particular flexible pouches of the uniformly flattype, also referred to as three-sided or four-sided sealed pouches(pillow pouch), or of the “doypack” type.

This secondary package (box) is placed on the shelf directly and soldwith the primary packages (pouches) inside it. A package is thusobtained called a “multi-pack” which can hold a single variety ormultiple varieties, the different pouches containing different products.

This type of packaging poses a number of problems.

The first problem is the problem of palletization. Two standards are atpresent applied in the trade. In the first case, the characteristicdimensions of the pallet are 800×1200 mm, whereas in the second case thecharacteristic dimensions are 1000×1200 mm.

The number of pouches per box varies greatly, depending on the type ofproduct and on how the latter is marketed. It is possible to have 7pouches per box for a 1 pouch per day use. The number of pouches canalso vary for the same product, for example during sales promotions(with 2 extra pouches free).

In the prior art, the pouches are arranged vertically in the box. Thus,the width of the box is imposed by the dimensions of the pouches, whichdimensions are chosen to be unique. The height of the box is likewiseimposed. However, the length of the box varies depending on the numberof pouches in it (the “case count”). Problems are therefore bound to beencountered with this type of box in terms of optimizing the palletconfiguration since a box of variable length cannot optimize theoccupation of the surface of the pallet for different “case counts”. Thedistribution or organization of the boxes in layers on the pallet has tobe modified when this “case count” is modified.

The second problem encountered is the manufacture of such boxes. Theyconventionally comprise side walls, a base and a lid, the base beingintegral with the side walls, whereas the lid can be added. For themanufacture of such boxes, use is made of a mandrel (metal preform)which shapes the material of the box by folding in a cavity. The cavityand the mandrel have, as characteristic dimensions, the width and lengthof the box. Thus, when the length of the box changes, it is alsonecessary to change the manufacturing tool. This increases themanufacturing difficulties and the final cost.

The invention therefore relates to a secondary package which contains aplurality of flexible primary packages or pouches and which permitsmaximum occupation of the surface of the pallet and is easy tomanufacture, irrespective of the number and type of pouches.

The invention thus makes available a pallet comprising a plurality ofboxes, these boxes containing pouches, characterized in that the pouchesare arranged flat in relation to the pallet.

According to one embodiment, the pouches are of the doypack type and areplaced head-to-tail in the boxes.

According to another embodiment, the boxes have widths and lengthscorresponding to dimensions, which are submultiples of 400×600 mm.

According to a further embodiment, the boxes open at their top.

According to another further embodiment, the boxes open at their side.

According to one embodiment, the boxes are obtained by folding with amandrel, the mandrel having the same width and length as the boxes.

According to another embodiment, the pallet measures 800×1200 mm.

According to a further embodiment, the pallet measures 1000×1200 mm.

The invention also relates to a box containing pouches, having widthsand lengths corresponding to dimensions which are submultiples of400×600 mm, the pouches being arranged flat in the plane defining saidwidths and lengths.

According to one embodiment, the pouches are of the doypack type and areplaced head-to-tail in the box.

According to another embodiment, the box opens at the top.

According to a further embodiment, the box opens at the side.

According to another further embodiment, the box is obtained by foldingwith a mandrel, the mandrel having the same width and length as the box.

The invention also relates to a method of manufacturing a palletaccording to the invention, comprising the following steps:

-   -   (i) provision of boxes containing pouches;    -   (ii) orientation of said boxes in such a way as to have the        pouches flat in relation to the pallet; and    -   (iii) palletization of said boxes.

The invention also relates to a method of manufacturing a box accordingto the invention, comprising the following steps:

-   -   (i) provision of an empty box having at least two dimensions        corresponding to dimensions, which are submultiples of 400×600        mm;    -   (ii) filling of said box with pouches, the plane of the pouches        corresponding to the plane defining said at least two        dimensions; and    -   (iii) closure of the box.

According to one embodiment, step (i) comprises a step of folding withthe mandrel, the mandrel having the same at least two dimensions as thebox.

According to another embodiment, step (ii) comprises inserting thepouches horizontally.

The invention also relates to a device for carrying out the method ofmanufacture according to the invention, comprising

-   -   (i) a conveyor belt delivering empty boxes, the boxes being        arranged on the conveyor belt in a plane containing said at        least two dimensions;    -   (ii) at least one conveyor belt delivering pouches and arranged        substantially perpendicular to the conveyor belt delivering        empty boxes, said pouches being arranged flat on said conveyor        belt;    -   (iii) an arm arranged above said conveyor belts and comprising a        gripper device at its end, said arm alternating between a        position for gripping the pouches and a position for filling the        box; and    -   (iv) a device for closing the box.

The invention also provides a packaging containing pouches, said pouchesbeing placed head-to-tail in the packaging, the packaging being of theflexible type with four welded sides.

The pouches may be of the doypack type or of a flat uniform or pillowpouch type and be placed so as to be staggered.

According to one embodiment, the packaging has width and lengthcorresponding to dimensions which are submultiples of 400×600 mm, thepouches being arranged flat in the plane defining the width and length.

The packaging may be of the top opening or side opening type. Accordingto one embodiment, the packaging further comprises a handle.

The packaging can further comprise a reclosing device.

The invention also provides a pallet comprising a plurality ofpackagings according to the invention, characterized in that the pouchesare arranged flat in relation to the pallet.

According to a further embodiment, the pallet measures 800×1200 mm.

According to a further embodiment, the pallet measures 1000×1200 mm.

The invention also provides a method of manufacturing a packagingaccording to the invention, comprising the following steps:

-   -   (i) provision of an empty packaging (100) having four welded        sides;    -   (ii) filling of said packaging with pouches; and    -   (iii) closure of the packaging.

The invention will further provides a method of manufacturing apackaging according to the invention, comprising the steps of:

-   -   (i) providing pouches in a mandrel;    -   (ii) winding a film about said mandrel    -   (iii) welding said film to obtain four welded sides (101 a, 101        b, 101 c, 101 d);    -   (iv) withdrawing said mandrel; and    -   (v) closing the packaging.

The invention finally relates to a method for manufacturing a paletteaccording to the invention, comprising the steps of:

-   -   (i) providing packagings containing pouches;    -   (ii) orienting said packagings so that the pouches are flat with        respect to the palette; and    -   (iii) palletizing said packagings.

The invention is now described in greater detail in the followingdescription and with reference to the attached drawings, in which:

FIG. 1 shows a box according to a first embodiment of the invention;

FIGS. 2 a and 2 b show a pallet loading configuration;

FIG. 3 shows a cross section through a box according to the invention;

FIG. 4 shows the web before being folded into the box according to thefirst embodiment;

FIG. 5 shows a device for filling the box according to the invention;

FIG. 6 shows a box according to a second embodiment of the invention;

FIG. 7 shows the web before being folded into the box according to thesecond embodiment.

FIG. 8 shows a the packaging of the invention diagrammatically as wellas the production method.

FIG. 1 depicts a package according to a first embodiment. The package isa cardboard box 1 containing a plurality of pouches 2 a, 2 b, 2 c, etc.These are arranged horizontally in the box. The latter thus has a widthand a length which are fixed by the characteristics of the pouch andtherefore remain fixed irrespective of the number of pouches in the box.Alternatively, once the dimensions of the box have been chosen, it ispossible to adapt those of the pouch. This box can therefore havedimensions “on the base” or on a pallet which are identical and whichcan in particular correspond to dimensions, which are submultiples of400×600 mm. The dimensions are submultiples of 400×600 mm when theyresult from the division of the 400×600 mm rectangle. Thus, thefollowing dimensions are submultiples: 300×400 mm (division by 2);200×400 mm (division by 3); 200×300 mm (division by 4); 130×300 mm(division by 6); 200×200 mm (division by 6); 150×200 mm (division by 8);100×300 mm (division by 8); 130×200 mm (division by 9); 130×150 mm(division by 12); 100×200 mm (division by 12); 100×150 mm (division by16). These dimensions permit optimized stacking of the pallet in layerssince it is always possible to reconstruct a base block measuring400×600 mm. A pallet configuration is shown in FIGS. 2 a and 2 b whichcorresponds to 800×1200 mm and 1000×1200 mm respectively, with a “basemodule” of 400×600 mm.

Such a box with pouches arranged flat when it is palletized thereforeaffords advantages in terms of palletization. As has been seen above, itis adapted to the two current standards. A variable number of pouchescauses only the height of the box to vary, but not the layer or palletbase configuration which remains the same. A variation of the height ofthe box changes only the number of layers (which incidentally is alreadyvariable from one country to another, the maximum admissible heights ofpallets varying from 2 m to 1.60 m). Automatic palletization is thuseasy to implement because no control operation is any longer necessary,only the programming of the number of layers. The logistics aretherefore improved.

The pouches situated in the box are of a conventional type. They can beof the uniformly flat type or preferably of the “doypack” type (namely asquare pouch having a surface forming a base and allowing the pouch tostand upright). The pouches of the doypack type will be preferred.Referring to FIG. 3, this shows a cross section through a packageaccording to the invention. The doypack pouches are again labelled 2 a,2 b, 2 c, etc. They alternate in a head-to-tail arrangement. Thispermits better utilization of the available volume in the box. Indeed,the at least partial superpositioning of the doypack pouches makes itpossible to increase the number of pouches per box (uniformly flatpouches losing a little useful volume at the four edges) and thusultimately the number of pouches per pallet. The partialsuperpositioning of the pouches also permits adaptation of the box withrespect to the length of the pouches, thus making it possible to allowfor the characteristic dimensions of, for example, 130×200 mm (or anyother submultiple of 400×600 mm close to the dimensions of the pouch inquestion). Such a doypack arrangement provides an interlocking effect.

The manufacture of the box is conventional; the box is obtained byfolding a cardboard web 3, the layout of which is shown in FIG. 4. Thebox 1 is formed by folding of a cardboard web 3. The latter has zonescorresponding to the different parts of the box. The zone indicated byhatching is the zone which will be pushed firmly by the mandrel (notshown) into the corresponding cavity or impression (alternatively it isalso possible to surround the mandrel with the web). This zonecorresponds here to the base 11 of the box. It is flanked by two sides12 and 13. The base 11 and the sides 12 and 13 are provided with flaps11 a and 11 b, 12 a and 12 b, 13 a and 13 b, respectively. These flapsare adhesively bonded to one another to form the box, the flaps 11 a, 12a and 13 a, on the one hand, and 11 b, 12 b and 13 b, on the other, thusforming the third and fourth sides 14 and 15, respectively. The box isthen filled with pouches by a suitable machine, the pouches beinggenerally inserted flat. The lid 16 (attached before or after filling)is then closed. It is also possible to make the lid integral with theother faces of the box, in which case the lid 16 is in the continuationof one of the flaps 11 a or 11 b.

FIG. 5 shows a device for filling the box according to the firstembodiment. It comprises, for example, a conveyor belt 21 deliveringempty boxes and, perpendicularly, two conveyor belts 22 and 23delivering pouches (arranged flat). According to a preferred variant,the pouches are placed the opposite way round on the conveyor belts inorder to achieve a head-to-tail arrangement in the box. The deviceadditionally comprises an arm 24 which rotates above the box and thepouches. The pouches are gripped, for example, with the aid of suctioncups 25 a and 25 b arranged at the end of the arm. The arm thusalternately fills the box with pouches from one conveyor belt and thenfrom the other conveyor belt. A device (not shown) for closing the boxis also used in a conventional manner.

FIG. 6 shows a package according to a second embodiment. The package isa cardboard box 1 containing a plurality of pouches 2 a, 2 b, 2 c, etc.These are arranged horizontally in the box. In contrast to the firstembodiment, the opening is via a face of the box. Alternatively, it ispossible to turn the box a quarter of a turn in such a way that theopening is at the top, the pouches then being arranged vertically (it isthis variant which is preferred for the second embodiment). Thedimensions of the box remain given for the pouches being arranged flat.In the second embodiment, the box is used (preferred variant) in anothersense than that for the palletization, in contrast to the firstembodiment. In the second embodiment, the pouches can have markings ontheir edge which makes it easier for consumers to identify them,particularly in the case of a multi-pack containing multiple varieties.

The manufacture of the box according to the second embodiment isconventional; the box is obtained by folding a cardboard web 4, thelayout of which is shown in FIG. 7. The box 1 is formed by folding acardboard web 4. The latter has zones corresponding to the differentparts of the box. The zone indicated by hatching is the zone which willbe pushed firmly by the mandrel (not shown) into the correspondingcavity or impression. This zone corresponds here to the base 11 of thebox. It is flanked by two sides 12 and 13, the latter also being flankedby the upper part 16. The base 11 and the side 13 and the top 16 areprovided with flaps 11 a and 11 b, 13 a and 13 b, 16 a and 16 b,respectively. These flaps are adhesively bonded to one another to formthe box, the flaps 11 a, 13 a and 16 a, on the one hand, and 11 b, 13 b,and 16 b, on the other, thus forming the third and fourth sides 14 and15, respectively. The box is then filled with pouches by a suitablemachine. The box is filled via the opening side (here 12), the pouchesthis time being introduced vertically (for example via the top, the boxbeing turned). In this case, the opening side is closed after fillingand not the top, as in the first embodiment.

The filling of these boxes according to the second embodiment is done aswith the boxes according to the first embodiment, the device describedwith reference to FIG. 5 also being adapted.

The cardboard box can be replaced by a box made of another rigidmaterial, such as polymer materials. In the invention, “box” means anypackage that can be stacked on a (rigid) pallet. Generally, these boxesare of substantially parallelepipedal shape. Other shapes distinct froma rectangle are also suitable, especially when they permit paving of thesurface of the pallet. The boxes otherwise have the conventionalcharacteristics of such secondary packages.

The pouches can contain various types of products, in particular pastes,granules, liquids, which may or may not be foods. These products willpreferably be moist food products. The pouches otherwise have theconventional characteristics of such primary packages.

In another embodiment, the packaging is a flexible packaging with fourwelded sides. With this type of packaging, the rigidity comes about notthrough the material constituting the (rigid) box but rather from theside welds, together with the filling, with the pouches arranged head totail. The pouches are for example of the doypack or flat type. They arepreferably staggered so as to obtain the required dimensions as regardsthe length of the packaging, while preserving the same width.

This embodiment is more particularly described in FIG. 8. Here, thepouches 2 a, 2 b, etc can be seen which are to be introduced into aflexible packaging 100 with four welded sides 101 a, 101 b, 101 c, 101d. The horizontal welds between the welds 101 a and 101 b and 101 c and101 d respectively, allow the packaging to be closed at the top andbottom.

The manufacturing method is illustrated in FIG. 8. In a first step, thepouches are presented and then introduced into the packaging 100. Oncethey have been introduced, two sides (generally the long sides) arefolded and welded together. The formation of a handle 103 ensuring easytransport can also be a provided for.

One can fill a packaging or bag which has already been welded and thenclose the top part (for example, at the handle), the bottom part beingpreferably already welded before the pouches are introduced. The bag canalso be welded directly onto the pouches: in this case a “prebox” in theform of a, preferably metal, mandrel is used with the pouches already inplace. Next, film is wound onto this mandrel (from a roll), after whichthe vertical (or longitudinal) welds are formed on the mandrel. Themandrel preferably has projections at the corners for facilitatingwelding.

The packaging is made from flexible film, which may be laminated or not,single-layer or multilayer. The film can be printed in a conventionalmanner. The film employed for producing a packaging as well as theproduction method for the packaging with four welded sides are furtherconventional.

The packaging can also include a side opening 102. This opening couldalso be on the top of the packaging or even on the bottom ifappropriate. This opening can be obtained conventionally by providingcut-outs in the film. A re-closing device can also be provided which, ina conventional manner, can be a tongue carrying a permanent adhesive.

Such a “flexible” packaging further offers advantages over the rigidbox. Cost-savings are achieve compared to the use of cardboard, notablyby minimizing the amount of product needed for the packaging and theprimary packagings. The amount of waste generated by the flexiblepackaging is less than the amount resulting from a rigid box and takesup less space for the consumer. The packaging allows films in modernmaterials offering multiple technical possibilities to be used. Finally,the flexible packaging allows better positioning and looks better onceplaced on supermarket shelves.

The invention is not limited to the embodiments which have beendescribed, but instead is open to numerous variants easily accessible tothe skilled person.

1. A packaging comprising: a plurality of pouches each pouch have a headand a tail, said pouches being placed head-to-tail in the packaging, thepackaging being of the flexible type with four welded sides.
 2. Thepackaging according to claim 1, in which the plurality of pouches are ofthe doypack type.
 3. The packaging according to claim 1, in which theplurality of pouches are of a flat uniform orv pillow pouch type and areplaced so as to be staggered.
 4. The packaging according to claim 1,wherein the packaging has width and length corresponding to dimensionswhich are submultiples of 400×600 mm, said pouches being arranged flatin the plane defining said width and length.
 5. The packaging accordingto claim 1, further including a top opening.
 6. The packaging accordingto claim 1, further including a side opening.
 7. The packaging accordingto claim 1, further including a handle (103).
 8. The packaging accordingto claim 1, further including a reclosing device.
 9. A palletcomprising: a plurality of packagings, the packagings comprising aplurality of pouches each pouch have a head and a tail, said pouchesbeing placed head-to-tail in the packaging, the packaging being of theflexible type with four welded sides; wherein the plurality of pouchesare arranged flat in relation to the pallet.
 10. The pallet according toclaim 9, wherein the pallet measures 800×1200 mm.
 11. The palletaccording to claim 9, wherein the pallet measures 1000×1200 mm.
 12. Amethod of manufacturing a packaging having a plurality of pouches eachpouch have a head and a tail, said pouches being placed head-to-tail inthe packaging, the packaging being of the flexible types, the methodcomprising the following steps: (i) providing an empty packaging havingfour welded sides; (ii) filling of said packaging with pouches; and(iii) closing of the packaging.
 13. A method of manufacturing apackaging having a plurality of pouches each pouch have a head and atail, said pouches being placed head-to-tail in the packaging, thepackaging being of the flexible type, the method comprising the stepsof: (i) providing pouches in a mandrel; (ii) winding a film about saidmandrel (iii) welding said film to obtain four welded sides; (iv)withdrawing said mandrel; and (v) closing the packaging.
 14. A methodfor manufacturing a palette having a plurality of packagings, thepackagings comprising a plurality of pouches, each pouch have a head anda tail, said pouches beings placed head-to-tail in the packaging, thepackaging being of the flexible type with four welded sides; the methodcomprising the steps of: (i) providing packagings containing pouches;(ii) orienting said packagings so that the pouches are flat with respectto the palette; and (iii) palletizing said packagings.